Latest from Materials

Aleksandr Matveev | Dreamstime
Thiti Tangjitsangiem | Dreamstime
'Availability of new foundry sand is already becoming a challenge, along with the need of providing new solutions to waste management,” according to the director of a metallurgical research center.
Branimir Ritonja | Dreamstime
Automotive cast parts.
Seesea | Dreamstime
Fire photo
Jacek Sopotnicki | Dreamstime
With deoxidized base iron, carbon levels can be increased to 3.30% C and alloying can be completely or nearly eliminated at the same time.
Compacted graphite iron output by SinterCast licensees for series production increased 30 yearonyear during the first quarter of 2014 to a new quarterly record of 170 million ldquoengine equivalentsrdquo mdash or 85000 metric tons

SinterCast Reports New Record with Q1 Tonnage

May 5, 2014
Commercial vehicle, pick-up demand paces increases in CGI series production Alternative to gray iron, aluminum New installations rise Ductile iron research continues

Recently SinterCast AB reported its first-quarter results for 2014, including the news of new-record volumes of compacted graphite iron produced according to its process route. During the January-March period, CGI output rose 30% year-over-year to an annualized rate of 85,000 metric tons worldwide. During March, the annualized rate reached 87,500 metric tons, the second-highest monthly output ever for CGI produced by the SinterCast route.

Stockholm-based SinterCast is the world’s largest supplier of process control technology for producing compacted graphite iron, a lightweight alternative to gray iron and aluminum for automotive component manufacturing.

The company listed several factors for the increased level of production, including a 100% year-on-year increase in the volume of SinterCast CGI for commercial vehicle castings. Factors behind that increase appear to include the new Euro 6 standard for commercial vehicle emissions; the increase in CGI volume in some North American pick-up platforms; and the introduction of a CGI version of Ford Motor Co.’s V-6 gasoline engine program; and a forthcoming CGI V8 diesel engine from Nissan early in 2015.

SinterCast also noted the first quarter marked the start of series production by Tupy, in Brazil, of a CGI cylinder head for an industrial engine. 

Tupy is among the largest-volume producers of SinterCast CGI, and adding industrial power products are part of its strategy to increase its CGI cylinder block and head output from the current 16% to 25% of the total.

SinterCast said new installations and technology updates continued during the first quarter, following record installation revenue in 2013. During January, SinterCast secured a new order for a System 3000 Plus from one of China's largest automotive parts manufacturers, to be installed at a greenfield CGI foundry in China.  The equipment will be installed this summer. 

SinterCast said it has ongoing discussions for other new installation, in Europe, Asia, and the Americas, and estimated that the combined potential of current series production programs and programs under development represents approximately 4.7 million “engine equivalents” (235,000 metric tons) per year within five years.

The group further estimated that current SinterCast CGI production programs have the potential for over 125,000 metric tons/year at full capacity.

SinterCast also reported that its ongoing development of a new process control technology for ductile iron production has been affected by the increased focus on CGI programs. However, it said the technical development continues and market opportunities remain available. In that light, SinterCast recruited a new senior research engineer to “expand and accelerate” its ductile iron technology development. 

“The SinterCast ductile iron technology is expected to provide additional benefit to customers by reducing magnesium consumption, improving mold yield, and reducing casting defects in the foundry, and by improving machinability,” the group noted.

About the Author

Robert Brooks | Content Director

Robert Brooks has been a business-to-business reporter, writer, editor, and columnist for more than 20 years, specializing in the primary metal and basic manufacturing industries. His work has covered a wide range of topics, including process technology, resource development, material selection, product design, workforce development, and industrial market strategies, among others. Currently, he specializes in subjects related to metal component and product design, development, and manufacturing — including castings, forgings, machined parts, and fabrications.

Brooks is a graduate of Kenyon College (B.A. English, Political Science) and Emory University (M.A. English.)